Pleated corrugated media and method of making

Abstract

A filter comprising a single length of filter material with a longitudinal axis wherein the length of filter material has a contour of elongated depressions and swells or apices substantially parallel to the longitudinal axis, the filter material further has folds substantially perpendicular to the longitudinal axis of the filter material forming pleats at substantially equal intervals. A process of making the filter and apparatus used in the process are a part of the instant invention.

1 . A filter comprising a single length of filter material with a longitudinal axis wherein said length of filter material has a contour of elongated depressions and swells substantially parallel to said longitudinal axis, said filter material further having fold lines substantially perpendicular to said longitudinal axis of said filter material wherein said length of filter material is folded at said fold lines forming pleats at substantially equal intervals.  
   
   
       2 . The filter of  claim 1  wherein said contour of elongated depressions and swells on one of said pleats engage said contour of elongated depressions and swells on adjacent pleats.  
   
   
       3 . The filter of  claim 1  wherein said contour of elongated depressions and swells is a corrugation in said filter material wherein said corrugation is a series of flutes, said flutes have a height in a range of approximately 0.1 to 25 mm.  
   
   
       4 . The filter of  claim 3  wherein said flutes have a height in a range of approximately 1 to 10 mm.  
   
   
       5 . The filter of  claim 4  wherein said flutes have a height of approximately 5 mm.  
   
   
       6 . The filter of  claim 1  wherein said contour of elongated depressions and swells is a corrugation in said filter material wherein said corrugation is a series of flutes, said flutes have a pitch in a range of approximately 1 to 50 mm.  
   
   
       7 . The filter of  claim 6  wherein said flutes have a pitch in a range of approximately 5 to 20 mm.  
   
   
       8 . The filter of  claim 7  wherein said flutes have a pitch of approximately 10 mm.  
   
   
       9 . The filter of  claim 6  wherein said flutes have a height in a range of approximately 0.1 to 25 mm.  
   
   
       10 . The filter of  claim 6  wherein said flutes have a height in a range of approximately ⅛ to ⅞ of said pitch.  
   
   
       11 . The filter of  claim 6  wherein said flutes have a height of approximately one half of said pitch.  
   
   
       12 . The filter of  claim 1  wherein said filter has a depth, said depth being a distance along said longitudinal axis between said fold lines, said depth of said filter being at least 10 mm.  
   
   
       13 - 14 . (canceled)  
   
   
       15 . The filter of  claim 1  wherein said single length of filter material is joined together at said swells and depressions with strips of material between said pleats.  
   
   
       16 - 20 . (canceled)  
   
   
       21 . The filter of  claim 1  wherein said pleats have an inlet end and an outlet end; said inlet and said outlet ends have a taper from said fold lines.  
   
   
       22 . The filter of  claim 1  wherein said pleats have an inlet end and an outlet end; said inlet and said outlet ends have an indentation approximate to said fold lines.  
   
   
       23 - 27 . (canceled)  
   
   
       28 . A filter comprising a plurality of pleats wherein said pleats are joined at folds and arranged in a zigzag pattern, said pleats having a first end with a first plurality of said folds and a second end with a second plurality of said folds, said first end being either an inlet or an outlet, said second end being the other of said inlet or outlet, said pleats each having a pattern of ridges and troughs wherein said ridges on one pleat substantially align with said troughs on an adjacent pleat.  
   
   
       29 . (canceled)  
   
   
       30 . The filter of  claim 28  wherein said pattern of ridges and troughs form a pleat height in a range of approximately 0.1 to 25 mm.  
   
   
       31 . The filter of  claim 30  wherein said pleat height is in a range of approximately 1 to 10 mm.  
   
   
       32 . The filter of  claim 31  wherein said pleat height is approximately 5 mm.  
   
   
       33 . The filter of  claim 28  wherein said ridges have a pitch between adjacent ridges on a pleat, said pitch between said adjacent ridges being in a range of approximately 1 to 50 mm.  
   
   
       34 - 68 . (canceled)